Download Smith Cast Iron Boilers GB250 SERIES User's Manual
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GB250-IM-5 42-9185 GB250 SERIES INSTALLATION, OPERATION & MAINTENANCE MANUAL AND REPLACEMENT PARTS LIST Gas-Fired Steam Cast Iron Boilers 175,000 to 400,000 Btuh Input Standing Pilot, Standing Pilot & Vent Damper, Intermittent Pilot, Intermittent Pilot & Vent Damper SECTION 1: INTRODUCTION Code Compliance. ....................................................2 Venting Requirements ..............................................3 Chimney Requirements ............................................3 Combustion Air Requirements ..................................3 Water Treatment........................................................4 Shipment of Boiler ....................................................4 SECTION 2: BOILER INSTALLATION Step 1: Locating/Setting Boiler..................................5 Step 2: Installing Steam Piping ................................6 Step 3: Installing Hydronic Components ..................7 Step 4: Venting Boiler................................................7 Step 5: Installing/Testing Gas Piping ......................10 Step 6: Wiring Boiler ..............................................11 SECTION 3: START-UP & OPERATION Sequence Of Operation ..........................................16 Prior To Start-Up ....................................................16 Start-Up & Adjustments ..........................................16 SECTION 4: MAINTENANCE Before Each Heating Season..................................19 How To Change Orifices ........................................20 Heating System Problems & Causes ......................20 Replacement Parts List ..........................................21 Warnings ................................................................25 WESTCAST, INC. 260 NORTH ELM STREET WESTFIELD, MA 01085 TEL. (413) 562-9631 FAX (413) 562-3799 www.smithboiler.com SECTION 1: INTRODUCTION CODE COMPLIANCE requirements of the authority having jurisdiction or, in the absence of such requirements, with the National Electrical Code, ANSI/NFPA No.70-latest edition. UL listed power limited circuit cable is almost universally approved for safety controls on heating equipment, either internally or externally, without protection of conduits or raceway. Boiler installations must conform to the requirements of the authority having jurisdiction or, in the absence of such requirements, to the National Fuel Gas Code ANSI Z223.1-latest edition. Where required by the authority having jurisdiction, the installation must also conform to the Standard for Controls and Safety Devices for Automatically Fired Boilers, ANSI/ASME CSD-1. For Canada, the installation must be in accordance with Standards CGA B149.1 and B149.2 Installation Codes for Gas Burning Appliances and Equipment and/or local codes. All electrical connections are to be made in accordance with Standard C.S.A. C22.1 Canadian Electrical Code, Part 1 and/or local codes. All electrical wiring must be in accordance with National Electric Code ANSI/NFPA No.70-latest edition and any additional state or local code requirements. If an external source is utilized, boiler, when installed, must be electrically grounded in accordance with BOILER MODEL A GB250-S-5L GB250-S-5H GB250-S-6 GB250-S-7 GB250-S-8 GB250-S-9 B 18" 22 1/2" 22 1/2" 26" 29 1/2" 18" 21 1/2" 25" 29 1/2" 28 1/2" 36 1/2" 32" DIMENSIONS C D 10 1/2" 7" 25" 10 1/2" 12 1/2" 14" 15 1/2" 17 1/2" 7" 8" 8" 25" 30" 30" 37" 37" FOR MODELS SUPPLIED WITH VENT DAMPER ADD 3 5/8" TO DIM. E E 9" 9" D SPILL SWITCH PRESSURE CONTROL *E 3" 9 3/8" PRESS. GAUGE 31 1/2" 8 15/16" PRESSURE RELIEF VALVE B 3" STEAM SUPPLY C 1/2" PLUGGED TAPPING 3/4" PLUGGED TAPPING LOW WATER CUT-OFF WATER LINE 3 3/4" 2 1/2" 26 7/8" 23 1/4" 2 1/2" ROLLOUT SWITCH 28 1/2" 20" 23 7/8" 23 1/4" 21" TRANSF. 115/24V 14 3/4" 2" RETURN REAR 14 3/4" 18 1/4" GAS VALVE 2" RETURN FRONT 16 1/2" 21 7/8" 6 3/4" -LEFT SIDE VIEW- A -FRONT VIEW- 18 1/8" -RIGHT SIDE VIEW- PROBE LOCATION FOR ELECTRIC LWCO. The following terms are used throughout this manual to bring attention to the presence of potential hazards or to important information concerning the product: DANGER: Indicates an imminently hazardous situation which, if not avoided, will result in death, serious injury or substantial property damage. CAUTION: Indicates a potentially hazardous situation which, if not avoided, may result in minor injury or property damage. WARNING: Indicates a potentially hazardous situation which, if not avoided, could result in death, serious injury or substantial property damage. NOTE: Used to notify of special instructions on installation, operation or maintenance which are impor tant to equipment but not related to personal injury hazards. 2 VENTING REQUIREMENTS 7. Any improper operation of the common venting system should be corrected so the installation conforms with National Fuel Gas Code, ANSI Z223.1-latest edition. When resizing any portion of the common venting system, the common venting system should be resized to approach the minimum size as determined using the appropriate tables in Appendix G in the National Fuel Gas Code, ANSI Z223.1-latest edition. For Canada, the provisions of B149.1 and B149.2 shall apply. When connecting to gas vents or chimneys, vent installations shall be in accordance with Part 7, Venting of Equipment, of the National Fuel Gas Code, ANSI Z223.1-latest edition, or applicable provisions of the local building codes. For Canada, the provisions of B149.1 and B149.2 shall apply. Vent connectors serving appliances vented by natural draft shall not be connected into any portion of mechanical draft systems operating under positive pressure. DANGER: A chimney which does not meet modern safety standards will result in a fire or deadly carbon monoxide poisoning of the building residents. When two or more appliances vent into a common flue, the area of the common flue should be at least equal to the area of the largest flue plus 50% of the areas of the additional flue or vent connectors. CHIMNEY REQUIREMENTS Chimney condition is of paramount importance for a safe and efficient boiler installation. All new and replacement installations must include a chimney inspection by a qualified individual or agency. Chimney construction materials must be compatible with the fuel being used. When an existing boiler is removed from common venting system, common venting system is likely to be too large for proper venting of appliances remaining connected to it. At time of removal of existing boiler, the following steps shall be followed with each appliance remaining connected to the common venting system placed in operation, while other appliances remaining connected to the common venting system are not in operation: Particular attention should be paid on all oil-to-gas conversions. Soot may have accumulated in chimney and/or degraded chimney liner. Most utilities require complete chimney cleaning. Others may require installation of new liner, spill switches or other chimney upgrades. Check with local utility for required safety precautions. 1. Seal all unused openings in common venting system. 2. Visually inspect the venting system for proper size and horizontal pitch and determine there is no blockage or restriction, leakage, corrosion and other deficiencies which could cause an unsafe condition. COMBUSTION AIR REQUIREMENTS Provisions for combustion air must be in accordance with the National Fuel Gas Code ANSI Z223.1 - latest edition, as well as all applicable local codes. If the boiler is installed in an unconfined space, adequate air will be available via normal infiltration. However, if building construction is unusually tight or the boiler is installed in a confined space (a space whose volume is less than 50 cubic feet per 1000 Btu/hr of gas input for all fuel burning equipment), adequate air for combustion must be provided by two openings: one located about 6” below the ceiling, the other about 6” above the floor. When communicating directly with the outside or through a vertical duct, each opening must have a minimum free area of one square inch per 4000 Btu/hr of gas input. Horizontal ducts to the outside must have a minimum free area of one square inch per 2000 Btu/hr of gas input. When ventilation is provided by openings in doors, etc. to adjoining spaces having adequate infiltration, each opening must have a minimum free area of one square inch per 1000 Btu/hr of gas input. 3. Insofar as is practical, close all building doors and windows and all doors between the space in which the appliances remaining connected to the common venting system are located and other spaces of the building. Turn on clothes dryers and any appliance not connected to the common venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they will operate at maximum speed. Do not operate a summer exhaust fan. Close fireplace dampers. 4. Place in operation the appliance being inspected. Follow the lighting instructions. Adjust thermostat so appliance will operate continuously. 5. Test for spillage at draft hood relief opening after 5 minutes of main burner operation. Use the flame of a match or candle, or smoke from cigarette, cigar or pipe. 6. After it has been determined that each appliance remaining connected to common venting system properly vents when tested as outlined above, return doors, windows, exhaust fans, fireplace dampers and any other gas-burning appliance to previous conditions of use. 3 WARNING: Adequate fresh air must be provided for combustion. Improper boiler operation and inadequate venting of deadly flue gases may otherwise result. NOTE: Boiler utilizes synthetic rubber seals. Water treatment chemicals and system cleaning chemicals must be compatible with this and all other construction materials. NOTE: Boiler employs atmospheric combustion. Combustion air must not be contaminated with halogenated hydrocarbon vapors, aerosol propellants or freon. Otherwise, boiler heat exchanger will be subject to corrosion, reducing boiler life. SHIPMENT OF BOILER Each boiler is shipped in a single carton. Draft hood is shipped in a separate carton on larger models. Optional Vent Damper When ordered, the vent damper is shipped in an individual carton packaged with the boiler. Mounting of the damper is required. WATER TREATMENT Water treatment is recommended in areas where water quality is a problem. A local water treatment company should be consulted to determine the requirements for your particular system and locality. WARNING: Installers must follow local regulations with respect to the installation of CO detectors and follow the manufacturer’s stated maintenance schedule for this boiler! NOTE: Boiler is not for use in systems where water is replenished. Minerals in the water can build up on the heat transfer surfaces and cause overheating and subsequent failure of the heat exchanger. ATTENTION: Observer les règlements règional à l’egard des détecteurs de monoxyde de carbone et observer entretien de manufacturier pour cette chaudière! 4 SECTION 2: BOILER INSTALLATION STEP 1: LOCATING AND SETTING THE BOILER ➤PROCEDURE A: Check that provisions for combustion air are in accordance with National Fuel Gas Code ANSI Z223.1-latest edition and all applicable local codes. In Canada, follow CAN/CGA B149(.1 or .2) installation codes. FIGURE 2.1 ➤PROCEDURE B: Check minimum clearances to combustibles are proper as shown. Local requirements may specify greater clearances & must be adhered to. Boiler shall be installed such that the gas ignition system components are protected from water (dripping, spraying, rain, etc.) during appliance operation and service. 6" 6" VENT DAMPER * TOP 1 1 1 1 1 1 1 1 1 1 1 1 1 18" 12" 12" RECOMMEND MORE FOR ACCESS TO VENT DAMPER POSITION INDICATOR * 52" FOR GB250-S-5L THRU GB250 S-7 58" FOR GB250-S-8 THRU GB250-S-9 WARNING: Never install boiler on combustible flooring without combustible flooring pan or on carpeting as heat damage and/or fire may result. CAUTION: Locate boiler so horizontal connecting flue pipe is as short as possible. Maximize height of vertical flue connector. NOTE: Do not loosen tie rods on absorption unit. They accommodate thermal expansion. Loss of boiler structural integrity and water leaks/damage may result. Step 1 Continued On Next Page 5 ➤PROCEDURE C: Check component positioning. 1. Remove all packing material from boiler. 2. Install on non-combustible floor only, unless local codes permit use and fabrication of a fireproof base (see Fig. 2.2). 3. Check that burners and controls are in the proper position. AA AAA AAAA AAA AA AAA AA AA AA AA A AA AA A AA AAA AAA AAAAAAAA AAAAAAAA AAAAA A 6" OVERHANG OF BLOCK AND SHEETMETAL ALL AROUND 4" HOLLOW CLAY TILE (TWO COURSES) OPENINGS THRU BLOCKS IN TOP COURSE TO BE AT 90 0 ANGLE TO OPENINGS THRU BOTTOM COURSE 6" 22 GAUGE SHEETMETAL FLOOR FIGURE 2.2 STEP 2: INSTALLING STEAM PIPING Typical piping connections are shown in Figure 2.3. All external piping must be supported by hangers, not by the boiler or its accessories. Proper steam piping practices must be followed at all times. Maintain proper clearances between piping and combustible material. Supply outlet must run full size from boiler to a header at least 24" above top of boiler. Condensate return piping should be connected to boiler through a "Hartford Loop." Install gate valves in supply and return. The supply and return lines should be equipped with drain cocks to drain sediment and sludge from lowest points of boiler. STEAM SUPPLY GATE VALVE SUPPLY TAPPING 3" NPT MUST BE CLOSE NIPPLE 24" MIN. HARTFORD LOOP RETURN TAPPING 2" NPT GATE VALVE WATER LINE C/L OF HARTFORD LOOP TO BE 2" BELOW WATER LINE RET URN COL DW ATE R FIL L 23-1/4" DRAIN COCKS FIGURE 2.3 6 STEP 3: INSTALLING HYDRONIC COMPONENTS A low-water cutoff must be installed to protect the unit from dry-fire. Screw extension nipple into 3/4" tapping on top of the absorption unit and install relief valve into top of nipple with the spindle in the vertical position (i.e., with the valve discharge in the horizontal)(See Figure 2.4). WARNING: No Valve of any type may be installed between the boiler and the relief valve to prevent accidental explosion from overpressure. PRESSURE RELIEF VALVE Most localities require the discharge piping to terminate within 6" of the floor. Check local code requirements if in doubt. Discharge piping must be of same size or larger than the relief valve outlet and should be run as short and straight as possible. Elbows in the discharge piping should be placed as close to the valve as possible. If valve discharge is to be drained away, the discharge piping must not be hard-piped to the drain piping (i.e., an open funnel or similar arrangement must be used). PRESSURE RELIEF VALVE DISCHARGE PIPING FIGURE 2.4 CAUTION: Piping must be installed from the relief valve discharge so there will be no danger of scalding personnel. STEP 4: VENTING BOILER DANGER: Drafthood, vent outlet and vent damper as supplied must not be altered in any was as proper boiler operation would be jeopardized. Flame rollout, fire or carbon monoxide poisoning will result. INSTALL SWITCH IN OPENING ON DRAFTHOOD Install draft hood on boiler. If the draft hood shroud has a hole near the relief opening for installing a spill switch, mount draft hood so the hole faces to the front of the boiler. Spill switches are provided on Model GB250-5L, GB250-5H, and GB250-6 boilers. Applicable boiler is equipped with a factory-mounted spill switch harness/mounting bracket assembly; spill switch is provided in plastic bag. See Figure 2.5. Install mounting bracket on outside surface of draft hood shroud with screws provided (HARNESS MUST BE ON OUTSIDE OF SHROUD). Install spill switch in hole in shroud (on outside surface) with screws provided. Plug wiring leads from harness/bracket assembly onto flat terminals on spill switch. CONNECT WIRE LEADS INSTALL MOUNTING BRACKET ON DRAFTHOOD FIGURE 2.5 If vent damper is supplied with boiler, it must be installed between the top of the draft hood and the flue pipe. See “Installing The Vent Damper” instructions. Connect draft hood to chimney or Class B vent. Flue pipe must be same diameter as the draft hood outlet. NOTE: Boiler will not operate unless wiring leads to spill switch are connected. 7 The flue or vent connectors must be installed flush with the inside chimney liner surface and sealed in place with furnace cement. Horizontal portions of the single wall and type B venting systems shall be supported by use of strap hangers or their equivalent. Vent supports should be placed a maximum of 15-feet apart and as required to prevent sagging. The vent connectors shall be pitched 1/4" per foot upwards towards the chimney or vent termination. Remove hairpin shipping clip which holds damper blade in closed position and observe that damper blade rotates slowly to open position. Do not force it closed as it may damage the gear train and void the warranty. The blade should move freely and without obstruction. Secure the vent damper housing to the drafthood outlet with sheet metal screws or pop rivets. Refer to Figure 2.8 for fastener locations. Install flue pipe over top of vent damper and secure to damper housing with sheet metal screws or pop rivets. DANGER: Only the boiler may be served by the vent damper. Do not attempt to use it to vent an additional appliance. This will cause fire or carbon monoxide poisoning. Attach vent damper cable to cable clamp on boiler left panel and join the Molex connector (see Figure 2.6 or Figure 2.6A). Installing Vent Damper The vent damper must be mounted directly on top of the draft hood. FLOW DIRECTION ARROW POINTS UP Locate the motor on the front side and position the cable so that it does not touch the metal surface of the drafthood (see Figure 2.6). If necessary, turn angle connector on vent damper upward until cable clears; tighten locknut to secure.The direction of the flow arrow imprinted on the vent damper must point upward. The damper position indicator, which is located on the side of the vent damper opposite the motor, must be visible. MAKE SURE MOTOR IS LOCATED ON FRONT SIDE MOUNT VENT DAMPER OVER DRAFTHOOD FIGURE 2.7 CAUTION: A minimum of 6" between vent damper and combustible materials must be maintained. The vent damper must be accessible for servicing and checking position indicator. PRESSURE CONTROL VENT DAMPER DRAFTHOOD PRESSURE CONTROL VENT DAMPER DRAFTHOOD THERMOSTAT CONNECTION THERMOSTAT CONNECTION CABLE BRACKET CABLE BRACKET TRANSFORMER TRANSFORMER PILOT CONTROL DK. BLUE DK. BLUE GAS VALVE THERMOSTAT CONNECTION THERMOSTAT CONNECTION FIGURE 2.6: Vent Damper Installation for Intermittent Pilot FIGURE 2.6A: Vent Damper Installation for Standing Pilot 8 of the largest flue plus 50% of the areas of the additional flue or vent connectors. ATTACH LOWER PORTION OF VENT DAMPER TO DRAFTHOOD OUTLET WITH 1/2" OR SHORTER SCREWS OR POP RIVETS AAAAA AAAAA AAAAA AAAAA AAAA AAAA AAAA AAAA When an existing boiler is removed from a common venting system, common venting system is likely to be too large for proper venting of appliances remaining connected to it. At time of removal of existing boiler, following steps shall be followed with each appliance remaining connected to the common venting system placed in operation, while other appliances remaining connected to common venting system are not in operation: 1. Seal all unused openings in common venting system. 2. Visually inspect the venting system for proper size and horizontal pitch and determine there is no blockage or restriction, leakage, corrosion and other deficiencies which could cause an unsafe condition. FIGURE 2.8 ➤PROCEDURE C: Install flue pipe between vent damper and chimney (6" minimum clearance required between flue pipe and combustibles). 3. Insofar as is practical, close all building doors and windows and all doors between the space in which the appliances remaining connected to the common venting system are located and other spaces of the building. Turn on clothes dryers and any appliance not connected to the common venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they will operate at maximum speed. Do not operate a summer exhaust fan. Close fireplace dampers. USE VENT SUPPORT(S) AS REQUIRED TO PREVENT SAGGING SINGLE WALL OR TYPE B FLUE PIPE A AA AA MAXIMUM 6 FT. APART 4. Place in operation the appliance being inspected. Follow the lighting instructions. Adjust thermostat so appliance will operate continuously. PITCH 1/4" PER FOOT SECURE FLUE PIPE TO VENT DAMPER 5. Test for spillage at draft hood relief opening after 5 minutes of main burner operation. Use the flame of a match or candle, or smoke from cigarette, cigar or pipe. 6. After it has been determined that each appliance remaining connected to common venting system properly vents when tested as outlined above, return doors, windows, exhaust fans, fireplace dampers and any other gas burning appliance to previous conditions of use. INSTALL FLUSH WITH CHIMNEY LINER SEAL WITH FURNACE CEMENT 7. Any improper operation of the common venting system should be corrected so installation conforms with the National Fuel Gas Code, ANSI Z223.1-latest edition. When resizing any portion of the common venting system, the common venting system should be resized to approach the minimum size as determined using the appropriate tables in Appendix G in the National Fuel Gas Code, ANSI Z223.1-latest edition. For Canada, the provisions of CAN/CGA B149(.1 or .2) shall apply. ADDITIONAL CHIMNEY REQUIREMENTS: Chimney condition is of paramount importance for a safe and efficient boiler installation. All installations must include a chimney inspection by a qualified individual or agency. Chimney construction materials must be compatible with the fuel being used. FIGURE 2.9 ADDITIONAL VENTING REQUIREMENTS: When connecting to gas vents or chimneys, vent installations shall be in accordance with Part 7, Venting of Equipment, of the National Fuel Gas Code, ANSI Z223.1-latest edition, or applicable provisions of the local building codes. Par ticular attention should be paid on all oil-to-gas conversions.Soot may have accumulated in chimney and/or degraded chimney liner. Most utilities require complete chimney cleaning. Others may require installation of new liner, spill switches or other chimney upgrades. Check with local utility for required safety precautions. Vent connectors serving appliances vented by natural draft shall not be connected into any portion of mechanical draft systems operating under positive pressure. DANGER: A chimney which does not meet modern safety standards will result in a fire or deadly carbon monoxide poisoning of the building residents. When two or more appliances vent into a common flue, the area of the common flue should be at least equal to the area 9 STEP 5: INSTALLING & TESTING GAS PIPING Connect the gas piping from the meter to the boiler using a pipe size which will result in a pressure drop of less than 0.3" W.C. for natural gas or 0.5" W.C. for propane. See Figure 2.10 for the appropriate gas pipe sizing and example. Install a full-sized sediment trap at the low point in gas line upstream of gas valve. Install a non-restrictive lubricated plug valve in the gas line close to the boiler. Install a ground joint union at the gas valve inlet to allow for servicing. Check local codes and utilities for any special requirements and procedures. Good piping practices should be followed at all times. See Figure 2.11 for a typical gas piping arrangement. All piping must be supported by hangers, not by the boiler or its accessories. Pipe joint compound (pipe dope) must be compatible with the fuel (natural gas or propane) being used. Maximum Capacity of Pipe in Cubic Feet of Natural Gas per Hour for Gas Pressures of 0.5 Psig or Less and a Pressure Drop of 0.3 Inch Water Column (Based on a 0.60 Specific Gravity Gas) Nominal Iron Pipe Internal Size, Diameter, 10 20 Inches Inches 1/4" 22 32 .326 3/8" 49 72 .493 132 1/2" 92 .622 278 3/4" 190 .824 1" 520 350 1.049 1,050 1-1/4" 730 1.380 1-1/2" 1,600 1,100 1.610 2" 3,050 2,100 2.067 2-1/2" 4,800 3,300 2.469 3" 8,500 5,900 3.026 4" 4.026 17,500 12,000 Length of Pipe, Feet 30 40 50 60 18 40 73 152 285 590 890 1,650 2,700 4,700 9,700 15 34 63 130 245 500 760 1,450 2,300 4,100 8,300 14 30 56 115 215 440 670 1,270 2,000 3,600 7,400 12 27 50 105 195 400 600 1,150 1,850 3,250 6,800 70 80 90 100 125 150 175 200 8 6 8 7 11 11 10 9 18 14 17 15 25 23 22 21 28 26 40 38 31 46 43 34 72 59 55 84 79 64 96 90 130 110 100 160 150 120 180 170 275 225 210 250 370 350 320 305 410 380 350 320 560 530 490 460 780 710 650 610 1,500 990 930 870 1,700 1,600 1,500 1,400 1,250 1,130 1,050 980 3,000 2,800 2,600 2,500 2,200 2,000 1,850 1,700 6,200 5,800 5,400 5,100 4,500 4,100 3,800 3,500 Maximum Capacity of Pipe in Thousands of Btu per Hour of Undiluted Liquefied Petroleum Gases (at 11 Inches Water Column Inlet Pressure) (Based on a Pressure Drop of 0.5 Inch Water Column) Nominal Iron Pipe Size, Inches 1/2" 3/4" 1" 1-1/4" 1-1/2" 2" Length of Pipe, Feet 10 275 567 1071 2205 3307 6221 20 30 189 152 393 315 732 590 1496 1212 2299 1858 4331 3465 40 50 129 114 267 237 504 448 1039 937 1559 1417 2992 2646 70 80 103 96 217 196 409 378 834 771 1275 1180 2394 2205 89 185 346 724 1086 2047 60 90 100 125 150 83 78 173 162 322 307 677 630 1023 967 1921 1811 69 146 275 567 866 1606 63 132 252 511 787 1498 Example: Boiler Model GB250-7 is to be installed. The distance from the existing gas meter installation site is 20 feet. What pipe size must be used? The local utility indicates the heating value of the natural gas being supplied is 1,000 Btu per cubic foot. Determine the cubic feet of gas per hour for above boiler model: 300,000 Btu per hour 1,000 Btu per cu. ft. = 300 cu. ft. per hour 1. Find 20 ft. in the upper portion of the table for natural gas under Length of Pipe, Feet heading. 2. Moving down the column, match the required capacity. The higher capacity is acceptable. In our case, it is 350 cu. ft. 3. Move to the left-hand column Nominal Iron Pipe Size, Inches to read required pipe size. In our case, it is 1". FIGURE 2.10 10 Testing Gas Piping BEAM DANGER: Before placing gas piping into service, carefully test it to assure every joint is gas tight. Bubble test all joints with a soap solution. NEVER TEST WITH AN OPEN FLAME AS FIRE OR EXPLOSION WILL RESULT. A RISER TO OTHER APPLIANCES PIPE CLAMP GAS METER MANUAL MAIN SHUT OFF VALVE For any pressure testing in excess of 1/2 psi, the boiler and its individual shutoff valve must be isolated from the piping system by disconnecting them and capping the outlet(s). For any pressure testing equal to or less than 1/2 psi, the boiler must be isolated from the piping system by closing its manual shutoff valve. A A A AAAAAAAAAA AAAAAAAAAA FIGURE 2.11 UNION GAS VALVE Minimum pressure required at the gas valve inlet is 5" W.C. for natural gas and 11" W.C. for propane. Maximum pressure allowable at the gas valve inlet is 12" W.C. If the gas pressure is above these limits, a pressure regulator must be installed. If the gas pressure is below these limits, contact the local utility. SEDIMENT TRAP STEP 6: WIRING THE BOILER WARNING: Turn off electrical power supply before servicing. Contact with live electric components can cause electric shock or death. the primary pressuretrol when facing the front of the boiler). Connect wiring assemblies (provided on boiler) from the low water cut-off or transformer to the primary pressure control and from the gas valve to the secondary pressure control as shown in Fig. 2.12. Do not readjust the secondary pressuretrol; its purpose is to interrupt thermocouple power to the gas valve in case the primary pressuretrol fails to function. FOR FIELD CONNECTION TO PRIMARY PRESSURE CONTROL (ON THE LEFT) WIRE ASS'Y. } FOR FIELD CONNECTION TO SECONDARY PRESSURE CONTROL (ON THE RIGHT) } } FOR FIELD CONNECTION TO PRIMARY PRESSURE CONTROL (ON THE LEFT) FOR FIELD CONNECTION TO SECONDARY PRESSURE CONTROL (ON THE RIGHT) } All electrical and control wiring must be installed in accordance with the codes listed in Section 1 of this manual. Follow the wiring diagram for your particular installation as shown in Figures 2.13 through 2.18. GB250-8 and GB250-9 natural gas standing pilot units have a secondary pressuretrol (located to the right of WIRE ASS'Y. WIRE ASS'Y. WIRE ASS'Y. 400 SERIES OR M & M PS804 LWCO TRANSFORMER TRANSFORMER GAS VALVE FOR BOILERS EQUIPPED WITH MCDONNELL-MILLER LWCO GAS VALVE FIGURE 2.12 FOR BOILERS EQUIPPED WITH 400 SERIES OR M&M PS804 FOR BOILERS EQUIPPED 400 SERIES OR M & M PS804 LWCO FOR BOILERS EQUIPPED WITH MCDONNELL-MILLER LWCO 11 For vent damper-equipped models, connect thermostat to blue leads (see Figure 2.6). NOTE: Boiler transformer must not be used to power external accessories (i.e., zone valves, relays, etc.) Otherwise, transformer will be overloaded and burn out. NOTE: If any of original wire supplied with boiler must be replaced, use similar wire of 105° C rating. Otherwise, insulation may melt or degrade, exposing bare wire. FIGURE 2.14: WIRING DIAGRAM & OPERATION SEQUENCE FOR BOILERS EQUIPPED WITH STANDING PILOT & MCDONNELL-MILLER #67 LOW WATER CUT-OFF (GB250-8 & GB250-9, N.G.) FIGURE 2.13: WIRING DIAGRAM & OPERATION SEQUENCE FOR BOILERS WITH STANDING PILOT & MCDONNELL-MILLER #67 LOW WATER CUT-OFF (EXCEPT GB250-8 & GB250-9, N.G.) 12 FIGURE 2.14: WIRING DIAGRAM & OPERATION SEQUENCE FOR BOILERS EQUIPPED WITH STANDING PILOT, VENT DAMPER & MCDONNELLMILLER #67 LOW WATER CUT-OFF (EXCEPT FOR GB250-8 & GB250-9, N.G.) FIGURE 2.13: WIRING DIAGRAM & OPERATION SEQUENCE FOR BOILERS EQUIPPED WITH INTERMITTENT PILOT, VENT DAMPER & MCDONNELL-MILLER #67 LOW WATER CUT-OFF 13 FIGURE 2.15: WIRING DIAGRAM & OPERATION SEQUENCE FOR BOILERS EQUIPPED WITH STANDING PILOT, VENT DAMPER & MCDONNELLMILLER #67 LOW WATER CUT-OFF (FOR GB250-8 & GB250-9, N.G.) FIGURE 2.16: WIRING DIAGRAM & OPERATION SEQUENCE FOR BOILERS EQUIPPED WITH INTERMITTENT PILOT, VENT DAMPER & 400 SERIES LWCO 14 FIGURE 2.17: WIRING DIAGRAM & OPERATION SEQUENCE FOR BOILERS EQUIPPED WITH STANDING PILOT, VENT DAMPER & 400 SERIES LWCO (EXCEPT FOR GB-250-8 & 9) FIGURE 2.18: WIRING DIAGRAM & OPERATION SEQUENCE FOR BOILERS EQUIPPED WITH STANDING PILOT, VENT DAMPER & 400 SERIES LWCO (GB250-8 & 9 ONLY) 15 SECTION 3: START-UP & OPERATION SEQUENCE OF OPERATION For sequence of operation of the particular boiler being installed, refer to Figures 2.13 through 2.18 in Section 2 of this manual. PRIOR TO START-UP Fill system with water until the water level indicator (sight glass) is approximately 2/3 full. This water level is 23" from the surface on which the boiler sits. Spill and rollout switches are mounted on Model GB250-5L, GB250-5H, and GB250-6 boilers. SYSTEM START-UP & ADJUSTMENTS Safe lighting and other performance criteria were met with the gas manifold and control assembly provided on the boiler when the boiler underwent tests specified in ANSI Z21.13. For boilers with a spill switch, the switch detects the escape of combustion products through the draft diverter relief opening and interrupts the power to the gas valve preventing unsafe boiler operation. Escape of flue products could be caused by a blocked or collapsed chimney or inadequate chimney draft. This is a manual reset-type device and can be reactivated by depressing the spill switch reset button mounted on the left of the boiler’s draft hood (see Figure 2.1 for switch location). WARNING: Keep boiler area clear and free from combustible materials, gasoline and other flammable vapors and liquids. Otherwise fire or explosion may result. 1. Check combination gas valve on boiler and make sure it is in the OFF position. For boilers with a flame rollout switch, the switch prevents flame rollout from the boiler combustion chamber, caused by blocked boiler flue passageways, by interrupting power to the gas valve to prevent unsafe boiler operation. This is a manual reset-type device and can be reactivated by depressing the rollout switch reset button mounted on the lower front jacket panel. Flue passages must be inspected by a qualified installer if this problem occurs, prior to resetting the button. 2. For vent damper-equipped models, with the thermostat set to call for heat, observe that vent damper position indicator rotates to the open position. Damper must be in the open position when appliance main burner is operating. a. After damper opens, spark should appear at the pilot ignition electrodes. b.Set thermostat to no longer call for heat. Spark should stop. Observe that damper position indicator rotates to the closed position. c. Set thermostat to call for heat. WARNING: If boiler cannot be restored to normal operation after re-setting of spill switch, or if flame rollout switch has tripped, do not attempt to put the boiler in operation. Immediately contact a qualified service professional. PRESSURE CONTROL 3. Light the boiler. For Model GB250 boilers with standing pilot see lighting instructions for Continuous Pilot on page 18. For Model GB250 boilers with intermittent pilot, see lighting instructions for Intermittent Pilot on page 18. PRESSURE RELIEF VALVE 4. Observe pilot and main burner flame (see Figure 3.2). All burner ports should be ignited and burn with a steady blue flame. PRESSURE GAUGE FIGURE 3.2 Q3451B INTERMITTENT IGNITION PILOT MODELS WATER LEVEL INDICATOR Q314A/Q309A CONSTANT PILOT MODELS NORMAL PILOT FLAME GAS VALVE NORMAL LIFTING (HARD FLAME) (TOO MUCH AIR) FIGURE 3.1 YELLOW TIPPING (MARGINAL) MAIN BURNER FLAMES 16 YELLOW FLAME (TOO LITTLE AIR) CAUTION: Never leave the job with yellow burning flames. This condition indicated poor combustion and will quickly carbonize the boiler, reducing efficiency and boiler life. It may also be an indication of improper venting or combustion air supply. If unable to adjust flame properly, consult your local utility. 5. Boilers are shipped from the factory with the primary air shutters on the main bur ner wide open. It is recommended these air shutters be left in the wide open position unless there is lifting of the flame above the burner ports. If there is lifting, the air shutters should be gradually closed until the lifting is eliminated. it may also be necessary to adjust the primary air shutters if the input rate is reduced by a change in the orifices. 6. After burner has been in operation for about 10 minutes, check gas input rate to boiler as follows: a. Make sure all appliances served by the meter are turned off during timing of gas input rate to the boiler. b. Measure the time in seconds that it takes for the boiler to use 10 cubic feet of gas. Divide 36,000 by the number of seconds (this is the number of cubic feet of gas used per hour). Multiply this figure by the heating value of the gas to obtain Btu input per hour. Example: A GB250-7 boiler takes 2 minutes to use 10 cubic feet of natural gas. The local utility indicated the heating value of the natural gas being supplied is 1000 Btu/cu ft. Therefore: 2 minutes = 120 seconds. 36,000 X 1000 = 300,000 Btu/hr 120 Therefore, the boiler input is correct. NOTE: Before calculating the input of the heating equipment, obtain the heating value of the gas from the local utility. 7. If input needs to be corrected, adjust combination gas valve pressure regulator. (Regulator is factory set at 31/2" W.C. for natural gas and 10" W.C. for propane.) Turn adjusting screw clockwise to increase gas flow (increase input). Turn adjusting screw counterclockwise to decrease gas flow (decrease input). In no case should final manifold pressure setting vary more than + .3" from factory-set pressures. If rated input cannot be obtained with adjustment, gas supply pressure or orifice size may be cause. Consult local utility and Smith. 8. Gas burner orifices supplied with boiler have been carefully designed to provide correct gas input rate for most gas conditions typically found in the U.S. and 17 Canada. Occasionally, however, local gas characteristics may not allow unit to be properly adjusted for input. If this is the case, local utility or Smith may recommend orifices be changed. When changing orifices follow the procedures detailed in Section 4 of this manual. 9. Start and stop burners several times by raising and lowering the thermostat setting. 10. After boiler has been firing long enough to raise boiler pressure above minimum setting of the primary pressuretol limit, check limit by turning its setting from maximum to minimum setting. This should turn boiler off. Return limit to desired setting. GB250-8 and GB250-9 also have a secondary pressuretrol (located to the right of the primary pressuretrol when facing the front of the boiler). DO NOT READJUST THE SECONDARY PRESSURETROL (it is factory-set and sealed at 15 psig). 11. Check boiler safety shutoff controls. a. For boilers with standing pilot, with boiler firing, disconnect thermocouple lead from the valve. The valve should close. b. For boilers with intermittent pilot, with boiler firing, disconnect wire connected to the "PV" terminal on the Honeywell S8600 control. The gas valve should close. 12. On initial start-up and prior to each heating season, boiler must be cleaned (see "Steam Boiler Cleaning Instructions" in Section 4 of this manual). WARNING: If you do not follow these instructions exactly, a fire or explosion may result with property damage, personal injury, or loss of life. A. BEFORE OPERATING smell all around the appliance area for gas. Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor. WHAT TO DO IF YOU SMELL GAS • Do not try to light any appliance. • Do not touch any electrical switch; do not use any phone in your building. Follow the gas supplier's instructions. • If you cannot reach your gas supplier, call the fire department. B. Use only your hand to push in or turn the gas control knob. Never use tools. If the knob will not push in or turn by hand, don't try to repair it; call a qualified service technician. Force or attempted repair may result in a fire or explosion. C. Do not use this appliance if any part has been under water. Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water. LIGHTING CONTINUOUS PILOT INSTRUCTIONS Standing Pilot Honeywell VR8300 and White Rodgers 36C04 - Natural or Propane Gas This appliance has a pilot which must be lit by hand. When lighting the pilot, follow these instructions exactly. 1. STOP! Read the safety information on this page. 2. Set the thermostat to lowest setting. 3. Turn off all electric power to the appliance. 4. Turn gas control knob clockwise to "OFF". (For WR-36C04) Push in gas control slightly and turn clockwise to "OFF" unless knob is pushed in slightly. Do not force. 5. Wait five (5) minutes to clear out any gas. Then smell for gas, including near the floor. If you then smell gas, STOP! Follow "A" in the safety information above. If you don't smell gas, go to the next step. 6. Remove the base door covering the top of the burners and enclosing the pilot. 7. Find pilot - Follow metal tube from gas control. The pilot is between the central burner tubes behind the base door. 8. Turn knob on gas control counterclockwise to "Pilot". 9. Push down and hold the red button. Immediately light the pilot with a match. Continue to hold the red button down for about one (1) minute after the pilot is lit. Release button and it will pop back up. Pilot should remain lit. If it goes out, repeat steps 4 through 9. • If button does not pop up when released, stop immediately and call your service technician or gas supplier. • If the pilot will not stay lit after several tries, turn the gas control knob to "OFF" and call your service technician or gas supplier. 10. Replace the base door. 11. Turn gas control knob counterclockwise to "ON". 12. Turn on all electric power to the appliance. 13. Set thermostat to desired setting. INLET OFF GAS GAS ON INLET OFF RESET BUTTON ON PILOT GAS CONTROL KNOB SHOWN IN "ON" POSITION GAS CONTROL KNOB SHOWN IN "OFF" POSITION Honeywell VR8300 WR-36C04 OPERATING INSTRUCTIONS Intermittent Ignition White Rodgers 36C74/Honeywell VR8304 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. STOP! Read the safety information on this page. Set the thermostat to lowest setting. Turn off all electric power to the appliance. This appliance is equipped with an ignition device which automatically lights the pilot. Do not try to light the pilot by hand. Turn gas control knob clockwise to "OFF". Wait five (5) minutes to clear out any gas. Then smell for gas, including near the floor. If you then smell gas, STOP! Follow "A" in the safety information on page 18. If you don't smell gas, go to next step. Turn gas control knob counterclockwise to "ON". Turn on all electric power to the appliance. Set the thermostat to the desired setting. If the appliance will not operate, follow the instructions "To Turn Off Appliance" and call your service technician or gas supplier. 18 INLET OFF GAS ON GAS CONTROL KNOB SHOWN IN "ON" POSITION WR-36C74 INLET GAS ON OFF GAS CONTROL KNOB SHOWN IN "OFF" POSITION Honeywell VR8304 TO TURN OFF APPLIANCE 1. Set the thermostat to lowest setting. 2. Turn off all electric power to the appliance if service is to be performed. 3. Turn gas control knob counterclockwise to "OFF". Do not force. SECTION 4: MAINTENANCE This boiler has been designed to provide years of trouble free performance in normal installations. Examination by the homeowner at the beginning of each heating season, and in mid-heating season, should assure continued good performance. In addition, the boiler should be examined by a qualified service professional at least once every year. 3. Check and clean burner assembly. Remove burner access panel. Lift burners up and to rear until burners are disengaged from orifices. Brush top of burners with soft bristle brush and blow out with air or vacuum. 4. Check gas manifold for proper position and reassemble burners to the manifold. Line up holes in burners with the orifices, and slide assembly back into position. BE SURE TO REINSTALL BURNERS WITH BURNER PORTS ON THE TOP SURFACE (UPRIGHT). DANGER:To avoid fire and explosion hazards: Do not store anything against the boiler or allow dirt or debris to accumulate in the area immediately surrounding the boiler. Keep boiler area clear and free from combustible materials, gasoline and other flammable vapors and liquids. Lint, paper or rags must not be allowed to accumulate near the burners. Do not place clothing on boiler to dry. 5. When a low water cut-off has been utilized, follow the manufacturer’s maintenance instructions. As a minimum, test the operation of electronic controls at least once a year. Remove, clean and inspect the probe. If the LWCO fails to operate properly it must be replaced. Float type controls should be flushed once a month during the heating season. NOTE: Do not draw water from heating system for cleaning. Minerals in the water can build up on the heat transfer surfaces and cause overheating and subsequent failure of the cast iron sections. 6. Follow "System Start-Up & Adjustments" procedures in Section 3 of this manual. NOTE: Do not obstruct the flow of combustion and ventilation air. Steam Boiler Cleaning Instructions The following procedures must be followed on initial start-up and if the presence of sediment, sludge or impurities hamper proper boiler operations. NOTE: If boiler is equipped with a low water cutoff, follow manufacturer's maintenance instructions. 1. With gate valves closed on supply and return lines, start burner and allow boiler to become pressurized so that the pressuretrol may be adjusted and set for limit cut-off desired (normally about 3 psi). Turn off burner and allow pressure to drop to 0 psi., then proceed with the following cleaning procedure. BEFORE EACH HEATING SEASON 1. Remove and inspect draft hood and vent piping (connecting draft hood to chimney or vent) for obstructions, soot accumulation, rust or corrosion. Clean and replace as necessary. Check tightness of joints; seal all joints where necessary. 2. Remove the pressure relief valve. 2. Check boiler flue passageways in the boiler sections for any blockage or soot accumulation. Remove draft hood, jacket top and flue collector. Using a flashlight, examine all flue passageways. 3. Add caustic soda (lewis lye) through this opening at the rate of one pound per thousand square feet of radiation capacity. Scout, Squirk or similar steam boiler cleaners may be used instead of lye. Trisodium phosphate (1/4#) is also an excellent cleaner. a. If passageways are free of soot and obstructions, replace flue collector and seal with furnace cement. 4. Provide pipe connection (full size) from pressure relief valve opening to a convenient drain to serve as a vent. b. If passageways need cleaning, remove burners as described in paragraph 3 below. Insert long-handle bristle flue brush down between section tubes and upward through sections from combustion chamber in both diagonal directions to remove carbon from finned surfaces. Vacuum debris. Replace flue collector and seal with furnace cement. 5. Fill the boiler with a manual fill valve until water starts to trickle from this pipe. 6. Fireboiler at sufficient rate to generate and maintain steam. Entrained water and impurities will then discharge (with steam) from open vent. Add water as necessary so that the low water cutoff does not shut off burner. c. Reinstall jacket top panel and draft hood. 19 HEATING SYSTEM PROBLEMS & CAUSES No Heat 7. Continue this process for a minimum of one hour. The process should continue until the steam is dry (no water coming from the vent when the water in the gauge glass is at a normal level, approximately 2/3 full). The time required could vary up to 3 hours. 1. Blown fuse or circuit breaker. 2. Switch turned off. 3. Pilot outage 4. IID system malfunction. 5. Flue damper not open. 6. Water level too low. 8. Turn burner to off position. While boiler is still hot, drain completely through boiler drain. Make sure that all low points in the return line are also completely drained. These areas could trap chemicals and dirt. Insufficient Heat 9. Close boiler drain and refill with clean untreated warm water. If warm water is not used, fill very slowly so as not to crack boiler sections. Fill until water overflows through vent pipe and runs clear. 1. Incorrect thermostat anticipator setting. 2. Low pressuretrol setting. 3. Boiler undersized or underfired. 4. Insufficient radiation. 10. Completely drain boiler again.Refill with clean untreated water to normal level. Odor, Excessive Moisture In Building 1. Leak in piping. 2. Carbon build-up in flueways. 3. Blocked chimney. 11. Remove vent drain piping and reinstall pressure relief valve. Open gate valves on supply and return lines. Turn on burner. System is now ready to operate. Yellow Flame, Carbon Build-Up 1. Unit overfired. 2. Air shutter misadjustment. 3. Wrong orifices. 4. Burning in burner mixing tube. HOW TO CHANGE ORIFICES 1. Shut off power supply and gas supply to the boiler. 2. Remove burner access panel. Lift burners up and to rear until burners are disengaged from orifices. Noise 1. Ignition or ignition noise due to incorrect air shutter adjustment. 2. Whistle due to burr on orifices. 3. Burner "fluting" due to air shutter opening too wide. 3. Check orifices for proper drill size. Size is stamped onto the body of the brass orifice (see Figure 4.1). Size can also be checked by using a pin gauge. 4. All orifices are screwed into the manifold and may be removed by using a 5/8" wrench or socket. Overheating 1. Wrong thermostat anticipator setting. 2. Bad thermostat location. 3. Bad thermostat. 5. Reverse procedures above to install orifices and burners. BE SURE TO REINSTALL BURNERS WITH BURNER PORTS ON TOP SURFACE (UPRIGHT). FIGURE 4.1 Boiler Model GB250-5L GB250-5H GB250-6 GB250-7 GB250-8 GB250-9 (1) Nat. Gas Drill Size 34 32 31 33 32 32 (2) Prop. Gas Drill Size 52 50 50 51 51 50 CAUTION: Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. Verify proper operation after servicing. 20 MODEL GB250 SERIES REPLACEMENT PARTS LIST ORDERING INFORMATION When ordering replacement parts, provide the model and serial number shown on the unit rating plate as well as the part number and name as shown in the parts list. Parts may be obtained from your local Smith heating contractor. REF NO. 1 2 3 4 5 9 11 NAME OF PART Jacket - Complete Jacket - Complete Jacket - Complete Jacket - Complete Jacket - Complete Base Pan Base Pan Base Pan Base Pan Base Pan Burner - N.G./L.P. Burner w/Pilot Bracket - N.G./L.P. Base Door Ass'y Base Door Ass'y Base Door Ass'y Base Door Ass'y Base Door Ass'y Manifold Manifold Manifold Manifold Manifold Burner Orifice - No. 31 (N.G.) Burner Orifice - No. 32 (N.G.) Burner Orifice - No. 33 (N.G.) Burner Orifice - No. 34 (N.G.) Burner Orifice - No. 52 (L.P.) PART NO. 59226 59227 59228 59229 59230 59058 59059 59060 59061 59062 59089 59091 59094 59095 59096 59097 59098 63276 59123 63278 59125 59126 59141 59142 59143 59144 59150 21 GB250 -5L GB250 -5H 1 1 GB250 -6 GB250 -7 GB250 -8 GB250 -9 1 1 1 1 1 1 1 1 1 5 1 1 5 1 1 6 1 7 1 8 1 1 9 1 1 1 1 1 1 1 1 1 1 1 6 5 9 10 9 10 8 5 5 5 6 8 REF NO. 13 14 15 16 17 18 19 22 23 24 25 26 27 28 29 31 — — 32 — 33 34 6 7 10 30 NAME OF PART Section, Rear Section, Intermediate Section, Front (No Coll Opening) Heat Exchanger/Assembled Block Heat Exchanger/Assembled Block Heat Exchanger/Assembled Block Heat Exchanger/Assembled Block Heat Exchanger/Assembled Block Port Seal - 5" Port Seal - 2" Pipe Plug 2" Sq. Hd. Low Water Cut-Off (CG400) Pigtail - 1/4" (CG400) Pressuretrol (PA404A) Press. Gauge (0-15 P.S.I.) Water Gauge Pressure Relief Valve - 15 P.S.I. Flue Collector Flue Collector Flue Collector Flue Collector Flue Collector Draft Hood - 7" For Spill Switch* Draft Hood - 8" For Spill Switch* Draft Hood - 8" Draft Hood - 9" Junction Box - 4"" x 4""" Silicone Sealant 11 oz. 3/8" Fiberglass Rope - 5 Ft. Block to Base Seal" Vent Damper - 7" w/Harness Ass'y Vent Damper - 8" w/Harness Ass'y Vent Damper - 9" w/Harness Ass'y Cable Bracket Manual Reset Spill Switch Manual Reset Rollout Switch Standing Pilot Pilot Ass'y N.G. - Q314-3679 Pilot Ass'y N.G. - Q314-3679 Pilot Ass'y N.G. - Q314-3679 Pilot Ass'y N.G. - Q314-3679 Pilot Ass'y N.P. - Q314-3679 Pilot Ass'y L.P. - Q314-3679 Pilot Ass'y L.P. - Q314-3679 Pilot Ass'y L.P. - Q314-3679 Thermocouple K16RA-36D Thermocouple K16RA-48D Gas Valve - N.G. VR8300C-4043 Gas Valve - N.G. WR36C04-439 Gas Valve - L.P. VR8300C-4035 Transformer - 120/24V 43VA PART NO. 3672 3671 3670 72403 72404 72405 72406 72407 60306 59168 61547 50090 61684 50493 60268 59199 61980 59204 59205 59206 59207 59208 59216 59217 59218 59219 60178 40440 GB250 -5L GB250 -5H GB250 -6 GB250 -7 GB250 -8 GB250 -9 1 3 1 1 1 3 1 1 1 4 1 1 5 1 1 6 1 1 7 1 1 1 1 4 4 1 1 1 1 1 1 1 1 4 4 1 1 1 1 1 1 1 1 5 5 1 1 1 1 1 1 1 6 6 1 1 1 1 1 1 1 7 7 1 1 1 2 1 1 1 1 8 8 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 60024 69496 69497 69498 59270 59273 59274 72366 70004 72367 72368 72369 72372 70007 72373 51006 59111 59131 59132 59133 50172 22 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 N/A N/A 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 REF NO. 6 10 — — 30 NAME OF PART Honeywell Intermittent Pilot System Pilot Ass'y N.G. - Q3451B-1103 Pilot Ass'y N.G. - Q3451B-1103 Pilot Ass'y N.G. - Q3451B-1103 Pilot Ass'y N.G. - Q3451B-1103 Pilot Ass'y N.G. - Q3451B-1103 Pilot Ass'y L.P. - Q3451B-1103 Pilot Ass'y L.P. - Q3451B-1103 Pilot Ass'y L.P. - Q3451B-1103 Gas Valve - N.G. VR8304P-4332 Gas Valve - L.P. VR8304P-3340 Gas Valve - L.P VR8304P-4330 Ignition Control S8600M-1013 Ignition Cable - 36" Lg. Transformer - 120/24 1006 43VA PART NO. 72354 70003 72355 72356 72357 72360 72361 70008 59136 59137 59138 51177 59308 50172 23 GB250 -5L GB250 -5H 1 1 GB250 -6 GB250 -7 GB250 -8 GB250 -9 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 N/A N/A 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 JACKET ASSEMBLY 1 32 29 27 33 28 34 24 25 23 22 17 26 18 13 19 15 14 16 5 31 6 30 2 4 7 3 10 9 24 11 WARNING Any appliance that burns natural gas, propane gas, fuel oil, wood or coal is capable of producing carbon monoxide (CO). Carbon monoxide (CO) is a gas which is odorless, colorless and tasteless but is very toxic. If your Smith boiler is not working properly, or is not vented properly, dangerous levels of CO may accumulate. CO is lighter than air and thus may travel throughout the building. Brief exposure to high concentrations of CO, or prolonged exposure to lesser amounts of CO, may result in carbon monoxide poisoning. Exposure can be fatal and exposure to high concentrations may result in the sudden onset of symptoms including unconsciousness. Symptoms of CO poisoning include: dizziness headaches nausea vision problems loss of muscle control weakness shortness of breath unclear thinking unconsciousness The symptoms of CO poisoning are often confused with those of influenza, and the highest incidence of poisoning occurs at the onset of cold weather or during flu season. A victim may not experience any symptoms, only one symptom or a few symptoms. Suspect the presence of carbon monoxide if symptoms tend to disappear when you leave your home. The following signs may indicate the presence of carbon monoxide: • Hot gases from appliance, venting system, pipes, or chimney escaping into the living space. • Flames coming out around the appliance. • Yellow colored flames in the appliance. • Stale or smelly air. • The presence of soot or carbon in or around the appliance. • Very high unexplained humidity inside the building. If any of the symptoms CO poisoning occur, or if any of the signs of carbon monoxide are present, vacate the premises immediately and contact a qualfied heating service company, the gas company or the fire department. To reduce the risk of CO poisoning, have your heating system “tuned up” by a licensed heating contractor or the gas company - preferably before each heating season. Also have the service company check your chimney or vent pipes for blockage. Your home should also be adequately ventilated, particularly if you have insulated your home. Only qualified, licensed service contractors should perform work on your Smith Boiler. WARNING Install, operate and maintain unit in accordance with manufacturer’s instructions to avoid exposure to fuel substances or substances from incomplete combustion which can cause death or serious illness. The State of California has determined that these substances may cause cancer, birth defects, or other reproductive harm. Also, install and service this product to avoid exposure to airborne particles of glasswool fibers and/or ceramic fibers known to the State of California to cause cancer through inhalation. 25 26 27 WESTCAST, INC. 260 NORTH ELM STREET WESTFIELD, MA 01085 TEL. (413) 562-9631 FAX (413) 562-3799 www.smithboiler.com